Vapor compression systems using an accumulator to prevent over-pressurization

ABSTRACT

An accumulator acts as a buffer to prevent over-pressurization of the vapor compression system while inactive. By determining the maximum storage temperature and the maximum storage pressure a system will be subject to when inactive, a density of the refrigerant for the overall system can be calculated. Dividing the density by the mass of the refrigerant determines an optimal overall system volume. The volume of the components is subtracted from the overall system volume to calculate the optimal accumulator volume. The optimal accumulator volume is used to size the accumulator so that the accumulator has enough volume to prevent over-pressurization of the system when inactive.

The present invention is a divisional application of U.S. patentapplication Ser. No. 10/742,037, filed Dec. 19, 2003.

BACKGROUND OF THE INVENTION

The present invention relates generally to a vapor compression systemincluding an accumulator sized to protect the system againstover-pressurization when inactive.

Chlorine containing refrigerants have been phased out in most of theworld due to their ozone destroying potential. “Natural” refrigerants,such as carbon dioxide and propane, have been proposed as replacementfluids. Carbon dioxide has a low critical point, which causes most airconditioning systems utilizing carbon dioxide as a refrigerant to runtranscritically, or partially above the critical point, under mostconditions, including when inactive. Under transcritical operations,pressure within the system becomes a function of both temperature anddensity.

A vapor compression system usually operates under a wide range ofoperating conditions. External atmosphere conditions, includingtemperature, can affect the pressure of the system while inactive. Thesystem components (compressor, condenser/gas cooler, expansion device,evaporator and refrigerant lines) are designed to withstand a maximumpressure, but exposure to higher pressures may result in damage to thecomponents. For most systems, the pressure in the system when notoperational is a direct function of the temperature that the system isexposed to. However, when this temperature is near or above the criticalpoint of the refrigerant, an additional factor must be considered. Forsupercritical fluids, the pressure in the system is a function of boththe temperature and density of the fluid. This is not typically aconcern for most refrigerants because their critical points are near orabove normal storage temperatures. For carbon dioxide (CO2) systems,however, this becomes an issue because the critical point is very low(88° F.).

A relief valve is typically incorporated into the system to protect thesystem and the components against over-pressurization. If pressure inthe system approaches an over-pressurization point, the relief valveautomatically opens to discharge refrigerant from the system anddecrease the pressure to a safe range to protect the components fromdamage.

Vapor compression systems are typically designed to be stored at acertain maximum temperature, and the system components are designed tobe able to withstand the maximum pressures associated with thistemperature. The higher the storage temperature, the higher the designpressure usually needs to be. When the storage temperature is near orabove the critical temperature of the refrigerant, the bulk density ofthe refrigerant is important in determining the system pressure, andtherefore the design pressure. This is shown schematically in FIG. 1,which illustrates how the system pressure changes above the criticalpoint for carbon dioxide as a function of both temperature and bulkdensity.

Prior vapor compression systems include an accumulator positionedbetween the evaporator and compressor that stores excess refrigerant.The accumulator is only sized to provide enough capacity for storingexcess refrigerant during operation to prevent the excess refrigerantfrom entering the compressor. The accumulator can also be used tocontrol the high pressure, and therefore the coefficient of performance,of the system during transcritical operation. However, the accumulatoris not sized to determine a maximum pressure when the system is inactiveor in storage.

Hence, there is a need in the art for a vapor compression system thatincludes an accumulator sized to prevent over-pressurization of thesystem while inactive, and a method for sizing such accumulator.

SUMMARY OF THE INVENTION

The present invention provides a vapor compression system including anaccumulator which acts as a buffer to prevent over-pressurization of thesystem while inactive.

When a fluid is near or above its critical point, pressure is a functionof both the temperature and the density. By knowing the maximum storagetemperature and the maximum storage pressure, a density of therefrigerant for the overall system can be calculated and used todetermine the ideal volume for the system.

The bulk density in the system is the system volume divided by the massof the refrigerant in the system. Therefore, by dividing the mass of therefrigerant by the maximum desired storage density, an overall desiredsystem volume can be determined. The total volume of the system withoutthe accumulator can be subtracted from the overall desired system volumeto calculate the optimal accumulator volume. The optimal accumulatorvolume is used to size the accumulator such that the accumulator canprevent over-pressurization of systems when stored at a storagetemperature near or above the critical temperature of the refrigerant inthe system.

These and other features of the present invention will be bestunderstood from the following specification and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The various features and advantages of the invention will becomeapparent to those skilled in the art from the following detaileddescription of the currently preferred embodiment. The drawings thataccompanies the detailed description can be briefly described asfollows:

FIG. 1 schematically illustrates a graph demonstrating how the pressureof carbon dioxide changes above the critical point as a function of bothtemperature and bulk density; and

FIG. 2 schematically illustrates a diagram of the vapor compressionsystem of the present invention, using an accumulator.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 2 illustrates an example vapor compression system 20 including acompressor 22, a heat rejecting heat exchanger (a gas cooler intranscritical cycles) 24, an expansion device 26, and a heat acceptingheat exchanger (an evaporator) 28. Refrigerant circulates through theclosed circuit system 20 through refrigerant lines.

In one example, carbon dioxide is used as the refrigerant. Becausecarbon dioxide has a low critical point, systems utilizing carbondioxide as a refrigerant usually run transcritically. Although carbondioxide is described, other refrigerants may be used.

The refrigerant exits the compressor 22 at a high pressure and a highenthalpy. The refrigerant then flows through the heat rejecting heatexchanger 24 at a high pressure. A fluid medium 30, such as water orair, flows through a heat sink 32 of the heat rejecting heat exchanger24 and exchanges heat with the refrigerant flowing through the heatrejecting heat exchanger 24. In the heat rejecting heat exchanger 24,the refrigerant rejects heat into the fluid medium 30, and therefrigerant exits the heat rejecting heat exchanger 24 at a low enthalpyand a high pressure. Heat rejection can occur in the supercriticalregion because the critical temperature of carbon dioxide is 87.8° F.,and the heat rejection fluid temperature is often higher than thistemperature. When the vapor compression system 20 operatestranscritically, the refrigerant in the high pressure section of thesystem is in the supercritical region where pressure is a function ofboth temperature and density.

A pump or fan 34 pumps a heat source fluid 44 through the heat sink 32.The cooled fluid medium 30 enters the heat sink 32 at the heat sinkinlet or return 36 and flows in a direction opposite to the direction ofthe flow of the refrigerant. After exchanging heat with the refrigerant,the heated fluid 38 exits the heat sink 32 at the heat sink outlet orsupply 40.

The refrigerant then passes through the expansion device 26, typically avalve which expands and reduces the pressure of the refrigerant. Afterexpansion, the refrigerant flows through the passages 42 of the heataccepting heat exchanger 28 and exits at a high enthalpy and a lowpressure. In the heat accepting heat exchanger 28, the refrigerantabsorbs heat from the heat source fluid 44, heating the refrigerant. Theheat source fluid 44 flows through a heat sink 46 and exchanges heatwith the refrigerant passing through the heat accepting heat exchanger28 in a known manner. The heat source fluid 44 enters the heat sink 46through the heat sink inlet or return 48. After exchanging heat with therefrigerant, the cooled heat source fluid 50 exits the heat sink 46through the heat sink outlet or supply 52. The temperature differencebetween the heat source fluid 44 and the refrigerant in the heataccepting heat exchanger 28 drives the thermal energy transfer from theheat source fluid 44 to the refrigerant as the refrigerant flows throughthe evaporator 28. A fan or pump 54 moves the heat source fluid 44across the heat accepting heat exchanger 28, maintaining the temperaturedifference and evaporating the refrigerant. The refrigerant thenreenters the compressor 22, completing the cycle. The system 20transfers heat from the low temperature energy reservoir to the hightemperature energy sink.

The system 20 further includes an accumulator 56 located between theheat accepting heat exchanger 28 and the compressor 22. The accumulator56 can store excess refrigerant in the system 20 and also to control thehigh pressure of the system 20, and therefore the coefficient ofperformance of the system 20 when operated transcritically. Duringoperation of the system 20, the accumulator 56 prevents excessrefrigerant from entering the compressor 22.

When a vapor compression system 20 is stored or transported in hotclimates, such as deserts, the refrigerant temperature increases due tothe high temperature of the surroundings. The increased temperatureincreases the pressure within the system 20 and can causeover-pressurization, leading to the activation of a pressure reliefvalve or bursting of a refrigerant line or system 20 component.

Bulk density is defined as the mass of the refrigerant in the systemdivided by the system volume. Since both the temperature and density ofthe refrigerant can affect the system pressure when the system is storedat or above the critical point of the refrigerant, the system volume ofa vapor compression system 20 also affects the pressure within thesystem when the system is stored at or above the critical point of therefrigerant. As the system volume increases at a given temperature at orabove the critical point of the refrigerant, the system pressuredecreases.

When the system 20 is inactive, the accumulator 56 may act as a bufferto reduce the increase in excess pressure and preventover-pressurization of the system 20. The size of the accumulator 56affects the overall volume of the system 20, and thus the maximumstorage pressure of the system 20. By increasing the volume of theaccumulator 56, the bulk density of the refrigerant in the system 20decreases, and thus the pressure of the refrigerant within the system 20decreases. By decreasing the volume of the accumulator 56, the pressureof the refrigerant within the system 20 increases. FIG. 1 shots thiseffect for a system using carbon dioxide as the refrigerant. In thepresent invention, the preferred size of the accumulator 56 iscalculated to prevent over-pressurization of the system 20 when inactiveor when transported. That is, the accumulator 56 is sized to be largeenough to prevent over-pressurization, but not too large to be overlyexpensive.

The volume of the accumulator 56 is determined based on the maximumdesign storage temperature and the maximum storage pressure of therefrigerant. As the storage temperature increases, the temperature ofthe refrigerant within the system 20 increases. Increasing therefrigerant temperature increases the refrigerant pressure within thesystem 20. Decreasing the refrigerant temperature decreases therefrigerant pressure within the system 20. The maximum storagetemperature of the refrigerant in the system 20 depends of the climate.In hot climates, the maximum storage temperature increases due to theincrease in the atmospheric temperature. In cooler climates, the maximumstorage temperature is lower due to the decrease in the atmospherictemperature. For system manufactured to global requirements, the higheststorage temperature will typically be chosen.

For system 20 with refrigerants having a relatively high criticaltemperature that is not near the maximum storage temperature of thesystem, the maximum storage temperature alone determines the maximumstorage pressure through the refrigerant saturation properties. This canbe seen in FIG. 1 for temperatures less than approximately 60° F. Forsystems 20 which use refrigerants having a relatively low criticaltemperature (such as carbon dioxide) both the maximum storagetemperature and the system bulk density determines the maximum storagepressure of the system 20. This can be seen in FIG. 1 for temperaturesgreater than approximately 60° F. That is, by knowing the maximumstorage temperature the refrigerant will reach when inactive, and themaximum design storage pressure, the optimal bulk density can becalculated and used to size the accumulator in the system.

The maximum design storage pressure of the system is generally limitedby the low pressure side of the system. During operation, the lowpressure side of the system will generally be exposed to pressures lowerthan when inactive or stored than when operating. For refrigerantshaving a relatively high critical point, the selection of the maximumdesign pressure is generally made with reference only to the maximumdesign temperature. For refrigerant having a relatively low criticalpoint, additional considerations, such as the manufacturing cost neededfor thicker walled components, need to be taken into consideration.Generally, the maximum storage pressure for a system using carbondioxide as the refrigerant is between 1000 and 2500 psi.

Density, when outside the saturated region, is a function of temperatureand pressure. Thus, if the maximum storage temperature and the maximumstorage pressure are known, the maximum storage bulk density can bedetermined. Volume can be calculated by dividing density with mass.Dividing the maximum storage density by the mass of the refrigerantdetermines an optimal overall system volume. The calculation below canbe used to obtain the ideal overall system volume:

The components in the system 20, except the accumulator 56, have a knowncomponent volume. These components include the compressor 22, the heatrejecting heat exchanger 24, the expansion device 26, the heat acceptingheat exchanger 28, and the refrigerant lines connecting the components.The accumulator 56 is the only component in the system 20 having anunknown volume. By subtracting the total component volume from theoverall system volume, the optimal accumulator volume can be determined.It is to be understood that the total component volume includes thetotal volume of all the components in the system 20, except for theaccumulator 56. Using the above equation, the optimal accumulator volumecan be calculated:

The above equation determines the optimal volume of the accumulatorbased on the maximum storage pressure of the refrigerant, the maximumstorage temperature of the refrigerant, the refrigerant mass, and thevolume of the system components. Preferably, the accumulator 56 volumeis selected within 80 to 120 percent of the calculated optimal size,resulting in a desired accumulator 56 size that protects the system 20against over-pressurization while inactive or during transport.

It should be understood that the example described for the single stagesystem using carbon dioxide is only an example. The optimal accumulatorsize can also be determined for multiple compression stage systems,systems which use internal heat exchangers, and systems with otheradditional system components, such as oil separators and filter dryers.The optimal accumulator size can also be determined for systems withmultiple heat rejecting heat exchangers 24, expansion devices 26, andheat accepting heat exchanger 28. In addition, the accumulator in thisexample has been described to be located between the evaporator and thecompressor. However, it is to be understood that the accumulator canalso be at another location. This invention also applies equally tosystems which use charge storage components located in other parts ofthe system, such as at the inlet of the evaporator or between thecondenser (or gas cooler) and the evaporator. Additionally, theaccumulator can also be divided into two or more charge storagecomponents located in different parts of the system, in which case theoptimal accumulator size applies to the sum of the volumes of each ofthe charge storage components.

The foregoing description is only exemplary of the principles of theinvention. Many modifications and variations of the present inventionare possible in light of the above teachings. The preferred embodimentsof this invention have been disclosed, however, so that one of ordinaryskill in the art would recognize that certain modifications would comewithin the scope of this invention. It is, therefore, to be understoodthat within the scope of the appended claims, the invention may bepracticed otherwise than as specifically described. For that reason thefollowing claims should be studied to determine the true scope andcontent of this invention.

1. A method of sizing an accumulator for a vapor compression systemcomprising the steps of: determining a maximum storage temperature of arefrigerant of the system; determining a maximum storage pressure of therefrigerant of the system; and utilizing the maximum storage temperatureand the maximum storage pressure to determine an optimal accumulatorvolume of an accumulator.
 2. The method as recited in claim 1, furtherincluding the steps of adding the accumulator having the optimalaccumulator volume, calculating a desired system volume using themaximum storage temperature and the maximum storage pressure,calculating a component volume of the system before the step of addingthe accumulator, and calculating the optimal accumulator volume bysubtracting the component volume from the desired system volume.
 3. Themethod as recited in claim 2, wherein the step of calculating theoptimal accumulator volume includes selecting a volume within 80 to 120percent of the optimal accumulator volume.
 4. The method as recited inclaim 2, wherein the step of calculating the optimal accumulator volumeincludes determining a density of the refrigerant at the maximum storagetemperature and the maximum storage pressure and dividing a mass of therefrigerant by the density of the refrigerant.
 5. The method as recitedin claim 2, wherein the step of calculating the component volumeincludes adding a total compressor volume of at least one compressor, atotal heat rejecting heat exchanger volume of at least one heatrejecting heat exchanger, a total expansion device volume of at leastone expansion device, a total heat accepting heat exchanger volume of atleast one heat accepting heat exchanger, and a total refrigerant linevolume of refrigerant lines.
 6. The method as recited in claim 5 whereinthe step of calculating the component volume further includes adding atotal internal heat exchanger volume of at least one internal heatexchanger, adding a total oil separator volume of at least one oilseparator, and adding a total filter dryer volume of at least one filterdryer.
 7. The method as recited in claim 6 wherein the step ofcalculating the component volume further includes adding a totaladditional components volume of any additional components.
 8. The methodof claim 1 wherein the step of determining the maximum storagetemperature further includes determining a maximum temperature therefrigerant will reach when the system is inactive
 9. The method ofclaim 8 wherein the step of determining the maximum storage temperaturefurther includes selecting a temperature between −50 and 200 degrees F.10. The method of claim 1 wherein the step of determining the maximumstorage pressure further includes determining a maximum pressure therefrigerant will reach when the system is inactive
 11. The method ofclaim 10 wherein the step of determining the maximum storage pressurefurther includes selecting a pressure between 1000 and 2500 psi.
 12. Amethod of sizing an accumulator for a vapor compression systemcomprising the steps of: a) determining a maximum storage temperature ofa refrigerant of the system, wherein the maximum storage temperature isa maximum temperature the refrigerant will reach when the system isinactive; b) determining a maximum storage pressure of the refrigerantof the system, wherein the maximum storage pressure is a maximumpressure the refrigerant will reach when the system is inactive; c)utilizing the maximum storage temperature and the maximum storagepressure to determine an optimal accumulator volume of the accumulator;and d) creating the accumulator having the optimal accumulator volume.13. The method as recited in claim 12, further including the steps ofcalculating a desired system volume using the maximum storagetemperature and the maximum storage pressure, calculating a componentvolume of the system, and calculating the optimal accumulator volume bysubtracting the component volume from the desired system volume.
 14. Themethod as recited in claim 13, wherein the step of calculating theoptimal accumulator volume includes selecting a volume within 80 to 120percent of the optimal accumulator volume.
 15. The method as recited inclaim 13, wherein the step of calculating the optimal accumulator volumeincludes determining a density of the refrigerant at the maximum storagetemperature and the maximum storage pressure and dividing a mass of therefrigerant by the density of the refrigerant.
 16. The method as recitedin claim 15, wherein the step of calculating the component volumeincludes adding a total compressor volume of at least one compressor, atotal heat rejecting heat exchanger volume of at least one heatrejecting heat exchanger, a total expansion device volume of at leastone expansion device, a total heat accepting heat exchanger volume of atleast one heat accepting heat exchanger, and a total refrigerant linevolume of refrigerant lines.
 17. The method as recited in claim 16wherein the step of calculating the component volume further includesadding a total internal heat exchanger volume of at least one internalheat exchanger, adding a total oil separator volume of at least one oilseparator, and adding a total filter dryer volume of at least one filterdryer.
 18. The method as recited in claim 17 wherein the step ofcalculating the component volume further includes adding a totaladditional components volume of any additional components.
 19. Themethod of claim 12 wherein the step of determining the maximum storagetemperature further includes selecting a temperature between −50 and 200degrees F.
 20. The method as recited in claim 12, wherein the step ofdetermining the maximum storage pressure further includes selecting apressure between 1000 and 2500 psi.